4g Conversion needs some parts
 

I have been replacing all of my battery cables with 4g welding wire. The battery and motor leads are easy, but the wire that goes on the "sweeper" part of the accelerator and the two wires on the charger plug have me stumped. Does anyone make replacement cables, or sell the crimpable ends, to convert those parts to 4g?

Or, is it even worth it to convert those wires? To me it seems like they would be a restriction if not scaled up with the rest of the cables.

Re: 4g Conversion needs some parts
 

There is no need to convert these wires to 4g. They don't have the current flow the batteries and motor demand.

Re: 4g Conversion needs some parts
 

So the wire on the sweeper arm doesnt affect any flow on the motor? Isnt that where to current comes from that is passed through the resistor?

I know the others dont because current only flows through them during charging, but I really dont know how the cart works beyond the basics of the sweeper contacts and the resistor.

Re: 4g Conversion needs some parts
 

Have you checked the schematics at the top of the section guide? You can follow the power line from the batteries to the motor. Maybe that can better answer your question.

Re: 4g Conversion needs some parts
 

It kinda helped, but the diagram isnt exactly like my cart is wired, so it makes it hard to follow the current. I guess Im gonna have to reassemble the cart and then trace it down.

Re: 4g Conversion needs some parts
 

Here are a couple of the best diagrams for a resistor cart that I've found.
They are both electrically the same, but each shows different parts of the circuits more clearly.

The wires from the charger receptacle only carry about 20 Amps, so 12Ga (or bigger) is sufficient.

The cable from the solenoid to the wiper arm carries total motor current, so it should be same gauge as rest of high current cables.

EZGO sells replacements, but they are probably 6Ga.
http://www.shopezgo.com/products/Wiper-Contact.html

Give Scottyb a yell. http://www.cartsunlimited.net/
He will most likely know if anybody has that cable assembly in a heaver gauge or the components needed to build one.

Re: 4g Conversion needs some parts
 

OK, so all of the diagrams Ive seen so far show the motor power feed coming from the sweeper board contact 4. My cart feeds the motor from the resistor stud 4. Is this something I should replace, or is it all the same since the current isnt actually going through any of the resistor coils?

Re: 4g Conversion needs some parts
 

It is the same point electrically.
I'm not sure, but you may have to choose between shorter cables or a current path with fewer connections in it.
If it were my choice, I'd go with fewer connections. (As shown in drawings)

Re: 4g Conversion needs some parts
 

Cool, Thanks.

Re: 4g Conversion needs some parts
 

Would it help, or for that matter hurt, anything to run a wire from both points to the motor?